Quality control process for repackaging agricultural chemical shuttle tanks

ABSTRACT

The agricultural chemical shuttle tank quality control and repackaging process of the present invention provides for standardized inspection, cleaning, repairing, and certification of the tanks so as to deliver precision crop protection chemicals to customers. The tanks include an ID label or bar code with information about the life cycle of the tank. The information is updated at one or more stages of the process. The tanks are classified according to chemical contents, and restricted for use in a single herbicide/pesticide classification throughout the tank life. A specialized automated wash station cleans the inside and outside of tanks of chemical residue and satisfies government environmental regulations for waste wash water.

BACKGROUND OF THE INVENTION

Agricultural chemical shuttle tanks are commonly used for transporting pesticides and herbicides from a bulk storage facility to the farmer's field. Such shuttle tanks typically may be 250 gallons or more. The tanks are normally returned to the bulk storage facility for re-filling and re-use. However, there are no industry standards regarding re-filling or repackaging of agri-chemicals in such tanks. The repackaging process for crop protection chemicals is labor intensive. Excess or leftover chemicals are commonly dumped before quickly rinsing the tank, and then refilling the tank with fresh chemicals. However, if a tank is improperly cleaned, chemical contamination from chemical residue can have critical consequences, such as damage to a farmer's crop. Prior art “rinse-and-go” operations fail to provide the quality control throughout the life cycle of the tank which is critical to avoid unnecessary and undesirable problems and consequences.

Therefore, a primary objective of the present invention is the provision of a quality control process for agricultural chemical shuttle tanks.

Another objective of the present invention is the provision of an improved repackaging process for pesticide and herbicide shuttle tanks.

Still another objective of the present invention is the provision of a standardized certification of agricultural shuttle tanks throughout the life cycle of the tanks.

A further objective of the present invention is the provision of a process for inspecting, cleaning, repairing, measuring, and certifying shuttle tanks to deliver precision crop protection chemicals for farmers.

Another object of the present invention is the provision of an automated wash system for cleaning agricultural shuttle tanks.

Yet another objective of the present invention is the provision of a system for tracking and monitoring shuttle tank usage throughout the life of the tank.

These and other objectives become apparent from the following description of the invention.

SUMMARY OF THE INVENTION

A quality control process for repackaging agricultural chemical shuttle tanks starts with the receipt of a shuttle tank having an identification label which is scanned to identify this tank's history. The tank is inspected for damage. Tanks are sorted into multiple groups, depending upon the chemical residue of the tank. Excess chemicals in the tank are extracted and a chemical neutralizer is sprayed on the interior and exterior of the tanks prior to washing. The tanks are then washed to remove the chemical residue. The tanks are washed in order from a first group having the least toxicity to the waste wash water to a last group having the most toxicity to the waste wash water. The waste water is filtered and then recycled for further washing of additional tanks. Then the tanks are refilled with additional agricultural chemicals. The tank is re-labeled with new history, including the chemical content.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a perspective view of a wash station which is one aspect of the quality control and repackaging process for agricultural chemical shuttle tanks, and with the wash doors closed, according to the present invention.

FIG. 2 is another perspective view of the wash station from an opposite corner as FIG. 1, and with the wash doors raised.

FIG. 3 is a front elevation view of the wash station, without the personnel platforms or inspection tables.

FIG. 4 is a rear elevation view of the wash station, without the personnel platforms or the inspection tables.

FIG. 5 is an end elevation view of the wash station, without the personnel platforms or the inspection tables.

FIG. 6 is a side elevation view from the opposite side of FIG. 5, without the personnel platforms and the roller tables.

FIG. 7 is a top plan view of the wash station, without the personnel platforms and the roller tables.

FIG. 8 is a flow chart of the bulk product receiving process, which is one aspect of the present invention.

FIG. 9 is a flow chart of the shuttle tank handling process, which is another aspect of the present invention.

FIG. 10 is a flow chart of the shuttle tank filling and shipping process, which is a further aspect of the present invention.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

The agricultural shuttle tank quality control and repackaging system and process of the present invention preferably is centered at the bulk chemical facility for filling and re-filling shuttle tanks for transporting herbicides and pesticides to farms or other warehouses. Each shuttle tank has an identification label, preferably in the form of a bar code. As each tank is received at the bulk chemical plant, the label is scanned to identify the life cycle of the specific tank, such as its contents, location, damage, and users. Each tank is then inspected for necessary repairs. Irrepairable tanks will be identified or labeled as “do not fill” and removed to an appropriate storage area. Damaged tanks which are repairable are tagged or otherwise identified for the repairs, to be completed later.

After the initial inspection, tanks are sorted and assigned by category grouping for storage. More particularly, the assignment is made according to a herbicide/pesticide classification, depending upon the type of chemical and the toxicity of the chemical. Throughout the life cycle of each specific tank, the chemical fills will be restricted to a single herbicide/pesticide classification, so as to eliminate or minimize any potential cross contamination. For example, the sorting of the tanks may be based upon whether the chemical is water or solvent based and/or the type of treatment required for cleaning the tank. Thus, Group 1 may be tanks requiring no pretreatment; Group 2 may be for tanks having solvent based chemicals or water based chemicals which require carbon adsorption treatment; Group 3 may be for tanks having solvent based chemicals or water based chemicals, with carbon adsorption treatment; and Group 4 may be for tanks having chemicals which can or/cannot be treated or must be disposed of.

From the group staging areas, each shuttle tank will be moved to the tank washing area and placed on the pre-treatment pan or table. The tank ID label is scanned. The tank pump is removed for inspection, repair and cleaning, apart from the tank. Each tank is inspected for excess chemical residue in the tank, and if present, the excess chemical will be extracted from the tank using an evacuation tube, such as a vacuum base. The extracted chemical will be appropriately stored and disposed. This extraction ensures that minimal residue will be left in the tank for removal during washing. At the pre-treatment pan, the tank's exterior and interior are sprayed with a bio-degradable neutralizer, prior to washing, so as to neutralize or reduce chemical concentration of any remaining chemical residues in, on, or around the tank. Then, the tank is moved into the washing chamber for a power wash operation.

Tanks in each group will be washed together, starting with the tank group having the lowest toxicity and progressing sequentially to the tank group having the highest toxicity to the wash water. All shuttle tanks within each group will undergo a similar wash cycle, though the wash cycles for different groups may vary, such as the wash time and/or the wash solution. Preferably, waste water from the wash system is filtered and recycled for each group, and for Group 1, to Group 2, to Group 3, to Group 4, or until the reused water is determined ineffective for continued use.

In the automated power wash chamber, an adjustable 360° spray nozzle is inserted into the tank, along with a waste water evacuation tube. As the spray nozzle ejects cleaning water or solution on the interior walls of the tank, the evacuation tubes simultaneously removes the waste water from the interior of the tank. Cleaning water is also sprayed on the exterior of the tank in the wash chamber. In one preferred embodiment, the wash cycle may last approximately 10 minutes using 140° F. water so as to remove dirt, contaminants, and chemical residue from the interior and exterior of the shuttle tank.

While each tank is being cleaned in the power wash station, the next several tanks to be cleaned are pre-treated at the pre-treatment table.

When the wash cycle is complete, the station doors are opened, the spray nozzle and evacuation tube are removed, and the tank moved to the external drip pan or table for a cleanliness inspection. If the tank did not meet the cleanliness standards, the tank can be re-washed in an additional wash cycle inside the chamber. Clean tanks are also inspected for excess waste water, which can be evacuated using the extraction tube. A new ID label or bar code will be placed on the clean tank, or an existing label or bar code will be updated, to confirm the cleaning time or date. The clean tanks are then moved to a storage area according to the chemical classification or group, or moved to a repair area to have repairs done The tanks are now ready for re-filling according to their specific limited chemical usage.

After cleaning, any necessary repairs to the tank are made. The chemical repackaging of the tanks begins with a specific work order from a distribution department. An operator retrieves a shuttle tank from the appropriate classification storage area and moves the tank to the chemical fill station. Prior to filling, the tank's identification label is scanned to check correct classification and prior cleaning and repair. If approved, the tank is weighed, and tank information is recorded for storage in a computer or other memory device. The bulk chemical is then precisely dispensed into the shuttle tank, the lids and covers are properly secured, sealed, and appropriate labeling is applied, prior to shipping or discharge of the tanks.

With the identification labels, each tank can be tracked extensively throughout its life cycle. The quality control of the chemical repackaging process prevents chemical contamination of crops so as to reliably deliver a precision crop protection product to the end users.

Wash Station

FIGS. 1-6 show one embodiment of a wash station for the tank washing process according to the present invention.

The wash station is generally designated in these figures by the reference numeral 10. The wash station 10 includes a washing chamber 12 having an entrance door 14 and an exit door 16. The doors 14, 16 are raised and lowered in a convenient manner to open and close the chamber 12. Preferably, the doors 14, 16 are automated and move simultaneously or in unison between the opened and closed positions at the end of each wash cycle. An entrance or pre-treatment table 18 is positioned adjacent the entrance door 14, and an exit table 20 is positioned adjacent the exit door 16. One or more personnel platforms 22 are provided adjacent the doors 14, 16 and/or tables 18, 20.

The wash station 10 includes various mechanical systems and components, including a wash water or fluid tank 24, a rinse water or fluid tank 26, a wash pump 28, and a rinse pump 30. Appropriate plumbing is provided between the tanks 24, 26, pumps 28, 30, and the 360° spray nozzle (not shown) in the wash chamber 12. Additional pumps 32, 34 are also operatively connected to the tanks 24, 26, respectively, and to additional spray nozzles (not shown) within the wash chamber 12 for washing and rinsing the exterior of the tank.

Other components of the wash station 10 include a water heater 36, a diverter 38, bag filters 40 for wash water and rinse water, a sump pump 42, a detail pump 44, and a filter 46 for the detail pump 44. A control panel 50 allows an operator to control the operation of the wash station 10 and its various components.

Shuttle tanks can be transferred to the wash station 10 using a forklift or any other convenient means for positioning on the pre-treatment inlet inspection table 18. Once pre-treatment is completed, an operator can open the doors 14 and manually move the tank into the wash chamber 12. The operator will insert the spray nozzle and evacuation tube (vacuum hose) into the tank. The operator then steps out of the chamber 12 and closes the automated doors 14, 16 before the wash cycle begins.

The wash and rinse cycles have adjustable timed cycles to clean both the interior and the exterior of the shuttle tank, depending on the tank classification (Groups 1, 2, 3, 4). Preferably, with the inside and outside wash stage pumps begin at the same time.

In one embodiment of the wash station 10, the pumps 28, 30 for washing and rinsing the inside of the tank include a three horse power motor with an output of approximately 5 GPM at 400 PSI. The pumps 32, 34 for washing the exterior of the tank have a five horse power motor with an approximate output of 100 GPM at 50 PSI. Each tank 24, 26 is preferably at least 80 gallons.

The wash station 10 also includes a filter system so that the wash and rinse water can be recycled in accordance with in strict federal and state regulations which generally preclude direct discharge of the water into a river, stream, lake, lagoon, body of water, or sewer system. The U.S. Environmental Protection Agency has established waste water discharge standards for a wide range of chemicals, known as the “Categorical Standards.” With the filtering treatment process of the present invention, discharge regulations of municipal water treatment systems are satisfied.

More particularly, the waste water of each chemical classification grouping (Groups 1, 2, 3, 4) is passed through a particulate filter, and then temporarily stored in a dedicated stainless steel tank. Next, the waste water is pumped through a micron bag filter, (such as 0.3 or 0.5 mm) and a pair of charcoal filters. Then, the group waste water is temporarily stored in another poly tank, for sampling and laboratory analysis for appropriate chemical constituents. The test analysis report results are compared to the acceptable group discharge standard of the EPA. Multiple holding tanks are provided for diluting the chemical residue to the appropriate group discharge level. If necessary, the waste water can be re-run through the charcoal filters. When the analysis indicates that the retained water satisfies the specific group standard, the water is discharged or released for disposal in accordance with regulation requirements.

For example, for tanks in Group 1 which require no pre-treatment, but preferably is filtered anyway, the waste water is sampled for total dissolved solids, total suspended solids, fats, oil and grease, and pH. For tanks in Group 2 (solvent or water based chemicals, carbon adsorption treatment), the waste water samples will be analyzed for the same characteristics as Group 1, as well as for herbicide and pesticide constituents. For Group 3 tanks (water or solvent based, carbon adsorption treatment), the waste water will be pumped through an activated carbon canister, and then sampled similar to Group 2 sampling. For Group 4 tanks (including some chemicals which cannot be treated on site), the waste water is pumped from the holding tank into DOT approved shipping container for transportation to a suitable disposal facility.

The wash station 10 is preferably constructed in multiple pieces which can be assembled. For example, the wash chamber 12 forms the center piece; the entrance inspection table 18 and adjacent platforms 22 form a piece on one side of the chamber 12, the exit inspection table 20 and adjacent platforms 22 form a third piece on the opposite side of the wash chamber 12, and the various wash station components 24-50 form another piece on the third side of the wash chamber 12. Each piece may be built on a base having slots for the forks of a forklift truck so that the pieces can be easily moved for assembly and disassembly.

FIGS. 8-10 show three flow charts for different phases of the quality control process of the present invention. In particular, FIG. 8 shows the flow chart describing the steps which are followed for the bulk product receiving process, beginning with an initial order for chemicals which are delivered by truck and unloaded into the bulk chemical storage system. FIG. 9 is a flow chart showing the shuttle tank handling process for inspecting, cleaning, and repairing the tank prior to refilling the tank with chemicals. FIG. 10 is a flow chart showing the shuttle tank filling and shipping process, following the process of FIG. 9.

The quality control process of the present invention provides a standardized, quality specifications and check points of inspection to guarantee a certified shuttle tank for chemical refill. The ID label system and automated wash cycle, assures that each shuttle tank undergoes the same process to reliably deliver a precision crop protection product to the customers. The inspection of the interior and exterior of the shuttle tanks assure cleanliness, certified removal of chemical residue, and tank condition and integrity. Outgoing tanks are tagged, sealed, and certified, thereby acknowledging the completion of the quality control repackaging process, thereby providing each tank with a traceable, life cycle history.

The invention has been shown and described above with the preferred embodiments, and it is understood that many modifications, substitutions, and additions may be made which are within the intended spirit and scope of the invention. From the foregoing, it can be seen that the present invention accomplishes at least all of its stated objectives. 

1. A quality control process for agricultural chemical shuttle tanks, comprising: receiving a shuttle tank; scanning a label on the tank to identify historical information about the tank; inspecting the tank for damage; sorting the tank into multiple groups according to chemical content of the tank; then washing the tank to remove chemical residue; and then re-filling the tank with additional agricultural chemical; and re-labeling the tank with updated historical information, including the added chemical.
 2. The process of claim 1 wherein the historical information includes contents, location, damage, and customers of the tank.
 3. The process of claim 1 further comprising labeling tanks having repairable damage.
 4. The process of claim 1 further comprising labeling tanks having irrepairable damage.
 5. The process of claim 1 wherein the washing will use varying time and cleaning agents for each grouping.
 6. The process of claim 1 further comprising washing the tanks in an order from a first group having the least toxicity to waste wash water to a last group having the most toxicity to waste wash water.
 7. The process of claim 6 further comprising filtering the waste wash water and re-cycling the filtered waste wash water for further washing.
 8. The process of claim 1 further comprising extracting excess chemical from the tank prior to washing.
 9. The process of claim 1 further comprising removing the tank identification label before washing.
 10. The process of claim 1 further comprising spraying the tank interior and exterior with a chemical neutralizer before washing.
 11. The process of claim 1 wherein the washing step includes the interior and exterior of the tank.
 12. The process of claim 1 wherein waste wash water in the tank is extracted during the washing step.
 13. The process of claim 1 further comprising inspecting the washed tank for cleanliness.
 14. The process of claim 1 further comprising re-washing unclean tanks.
 15. The process of claim 1 further comprising inspecting the washed tank for excess waste water and extracting excess waste water.
 16. The process of claim 1 wherein the re-fill is limited to a same classification of additional chemical as the chemical last used in the tank.
 17. The process of claim 1 further comprising sampling waste wash water for compliance with governmental regulations.
 18. A repackaging process for agricultural chemical shuttle tank, comprising: a) placing a bar code on a shuttle tank, the code providing data about the history of the tank; b) adding a liquid chemical to the tank at a base station; c) transporting the tank to an agricultural field; d) discharging at least a portion of the liquid chemical from the tank in an agricultural field application; e) returning the tank to the base station; f) inspecting the tank for damage; g) cleaning the tank to eliminate any residue of the liquid chemical; h) refilling the tank with new chemical; i) updating data on the bar code of the tank to include information about steps b, e, f and h.
 19. The process of claim 18 wherein steps b-h are repeated.
 20. The process of claim 18 wherein the wash step uses water and further comprising recycling the wash water for cleaning additional tanks. 